Ceramic material

ABSTRACT

The invention relates to a ceramic material comprising at least one transition metal silicate and/or transition metal disilicate. The ceramic material can be characterized by having one or more monosilicates, one or more disilicates and mixtures consisting of monosilicates and disilicates.

[0001] The invention relates to a ceramic material which comprises at least one transition metal silicate and/or transition metal disilicate.

[0002] Worldwide known recoverable reserves of nonrenewable (fossil) energy sources amount to about 1200 Mrd. t BCU (BCU=bituminous coal units=29.3 10⁹ J). The principal energy carrier is coal. It makes up 49.2%, of which 43.5% is hard coal and 5.7% is lignite. Thus processes for driving coal-fired gas power plants and steam power plants (G & S power plants) as well as other modern power plants have been developed to use pressurized coal dust firing technology (PCDF technology). The PCDF technology utilized in G & S power plants does not utilize natural gas, but rather coal under high pressures (10 to 20 bar) and burns the coal to produce hot gas under pressure which is used to drive a gas turbine. Because of the mineral content of the coal, the resulting flue gas must however be cleaned before it can be used in the gas turbine. Liquid slag particles and their main component, SiO₂, especially must be removed. Up to now for this purpose a direction-change system has been provided in which the flue gas impinges on the surfaces of ceramic materials and the slag which there agglomerates can flow off in a liquid film which is removed by gravitation from the surfaces and thus from the flue gas stream. The deflection system includes precipitating devices for the slag, especially in the form of baffle plates or ball packings. For the liquid ash separation at the present time Cr₂O₃ or melt-cast Cr₂O₃-containing ceramics are used since Cr₂O₃ is the single ceramic which has sufficient corrosion-resistance in contact with a flowing coal slag. The stability of the chromium oxide derives from the fact that Cr₂O₃ undergoes no chemical bonding with the main component of the coal slag, SiO₂, and does not form ternary mixed oxides. Similar characteristics with respect to reactions, in contrast with SiO₂, for some time have been only UO₂ and ThO₂, but because of their radioactivity, these compounds have not been used.

[0003] A problem with Cr₂O₃-containing ceramics is that they under power plant conditions and high steam pressures tend to evaporate, whereby in an oxidizing atmosphere the volatile species Cr₂O₃ and CrO₂(OH₂) arise. Under PCDF conditions, the vaporization is yet more intensive since there a significantly higher temperature prevails on the one hand and on the other the chromium evaporation is about an order of magnitude more intensive because of the sodium oxide and potassium oxide of the carbon slag so that Cr₂O₃-containing ceramics also because of a cancer-producing effect of vaporized Cr⁶⁺ compounds cannot be treated as appropriate ceramics for liquid ash separation over longer periods.

[0004] Especially for the PCDF technology, ceramic materials are required that have the following characteristics:

[0005] 1) Thermodynamic stability and corrosion-resistance at temperatures between 1250 and 1500° C. in an oxidizing atmosphere.

[0006] 2. Low solubility and chemical stability in contact with a flowing coal slag with constituents like: SiO₂, Al₂O₃, CaO, Fe₂O₃, MgO, K₂O and Na₂O.

[0007] 3. No formation of volatile toxic products.

[0008] It is therefore the object of the invention to provide a ceramic material which has long-term stability at high temperatures in oxidative and/or moist milieus, especially for the deposition of liquid components from flue gas in power plants and refuse incinerator apparatus and which can be used without the liberation of volatile, toxic compounds. Chemical reactions with SiO₂ are suppressed.

[0009] The objects are achieved with a ceramic material in accordance with claim 1 and encompass at least one transition metal silicate or a transition metal disilicate. With “transition metals” a metal according to the IUPAC nomenclature (1985) is meant. The transition metal can be an element from the third through twelfth subgroups (scandium to mercury, atomic numbers 21-30, 39-48 and 57-80) of the periodic table, also including the elements of the lanthanide series (lanthanum to lutetium, atomic numbers 57-71) as well as the elements of the actinide series (actinium through lawrencium, atomic numbers 89-103).

[0010] Transition metal silicates are comprised of at least equivalent of transition metal oxides and one equivalent SiO₂.

[0011] They have, like the transition metal disilicates with trivalent transition metals as oxidic components, a mixing gap to SiO₂. The expression the mixing gap is primarily used in the description of phase diagrams. Thus Cr₂O₃ forms with SiO₂ over the entire range of variation (0 to 100% SiO₂ or 100% Cr₂O₃ to 0% Cr₂O₃) a mixing gap, i.e. in the entire phase diagram Cr₂O₃—SiO₂ there is no formation of a ternary phase from SiO₂ and Cr₂O₃. Above the melting point of SiO₂ (1725° C.) there is not only liquid SiO₂ but also solid Cr₂O₃ without a reaction occurring. This applies also for the claimed transition metal silicates and the transition metal disilicates, which as solids at high temperatures do not react with SiO₂.

[0012] Advantageously the ceramic is characterized by a transition metal from the third or fourth subgroup of the periodic table or the group of lanthanides (claim 2). These are stable at temperatures above 1300° C. in moist oxidative environments.

[0013] In a feature of the invention according to claim 3, the ceramic is characterized by a silicate of the formula M₂SiO₅ or M₂Si₂O₇, (where M=transition metal). The term silicate encompasses corresponding monosilicates or disilicates with a transition metal oxide of the formula M₂O₃ and one equivalent of SiO₂ (for transition metal monosilicates) and two equivalents of SiO₂ (for transition metal disilicates). The transition metal is in the trivalent state.

[0014] Especially advantageously the ceramics comprise scandium, yttrium, lanthanum, cerium, samarium and/or dysprosium predominantly as metal oxides (claim 4). With these compounds, monosilicates and disilicates are obtainable which empirically are found to have unusual stability at temperatures higher than 1300° C. The metal oxides are economical and easily obtainable commercially. Mixtures of different metals within one ceramic are possible.

[0015] It has been found that a ceramic can also be characterized by a silicate of the formula MSiO₄ (where M=transition metal) (claim 5). The transition metal is then in a quadrivalent state in the metal oxide (MO₂), and the silicate contains then one equivalent of SiO₂.

[0016] If the ceramic is characterized primarily by zirconium and/or hafnium as the metal oxide, the monosilicate which is formed is especially corrosion-resistant and has long-term stability at high temperatures. In the use of several different quadrivalent transition metals, like in the case of use of several different trivalent transmission metals, mixtures of the transition metal silicates in one ceramic are possible.

[0017] In a further feature of the invention the ceramic contains 50 to 66 mol % SiO₂ (claim 7). Apart from the previously-mentioned mixtures of monosilicates or of disilicates in one ceramic, mixtures of mono and disilicates in a single ceramic are also possible. As a consequence a high variability in the selection of the starting compounds is possible and as a consequence a wide spectrum of monosilicates and/or disilicates can be synthesized.

[0018] Especially advantageous are the ceramics which are characterized by a melting point greater than 1500° C. For these high temperature-resistant ceramics the fields of use in technology are substantially unlimited and can include, for example, the liquified ash separation in pressurized carbon dust firing (PCDF).

[0019] In a further feature of the invention, the ceramic comprises a refractory ceramic which is surface-coated with transition metal silicates and/or transition metal disilicates (claim 9). The refractory ceramic then comprises a protective layer with the application of transition metal silicates and/or transition metal disilicates s processes for the surface coating, for example, the hot isostatic pressing (HIP), cold isostatic pressing or sintering can serve. The transition metal silicate or transition metal disilicate refractory ceramic, by comparison with hitherto used ceramics consisting of solids composed entirely of Cr₂O₃ materials, have significant material cost savings.

[0020] Advantageously separating apparatus, especially for the liquified ash separation in the pressurized carbon dust firing technology, comprises such a ceramic (claim 10). By “separating apparatus” is meant packings, baffle plates, porous ceramics and others without the need to set out especially the choice of geometry. It is therefore not significant whether one uses a ball packing or packing of some other geometry. Separating apparatus like packings, baffle plates or porous ceramics which comprise such a ceramic in accordance with the invention enable a liquified ash separation without liberation of volatile toxic components.

[0021] Especially advantageously, a coal-operated gas and steam power plant comprises such a ceramic (claim 11). Thus the pressurized coal dust firing technology is usable also for gas and steam power plants.

[0022] Furthermore, melting vats, especially for vitrification technology can comprise such ceramics (claim 12). In this manner toxic components of the filter ash from garbage incineration can be fixed. One then utilizes the fact that the transition metal silicates and/or transition metal disilicates are chemically inert with respect to SiO₂. It is also conceivable to use a ceramic with transition metal silicates and/or metal disilicates, based upon their electrically insulating characteristics, as sealing and insulating material in the edge regions of fuel cells or fuel cell stacks.

[0023] The object of the invention is, in addition, to provide a method of operating a coal-firing gas and steam power plant (claim 13). In that case

[0024] a fuel is combusted under pressure;

[0025] a hot gas is conducted onto a separating device which comprises ceramic with transition metal silicates and/or transition metal disilicates;

[0026] the liquid particles are removed.

[0027] The ceramic can comprise transition metal silicates (one or more monosilicates), transition metal disilicates (one or more disilicates) or also mixtures of mono and disilicates. Through the mixing gap of SiO₂, the main component of the coal slag, efficient removal of the latter by agglomeration from the flue gas can be effected whereby gas power plants and steam power plants can be fired with coal without the liberation of toxic species (pressurized coal dust firing).

[0028] A method of operating a coal, wood, biomass or clarifier sludge gasifier is characterized by the steps of:

[0029] gasifying fuel or substoichiometrically burning fuel,

[0030] guiding the hot gas onto a separating device which comprises a ceramic with transition metal silicates and/or transition metal disilicates,

[0031] removing the liquid particles (claim 14).

[0032] By substoichiometrically is meant a combustion or gasification in which the oxygen is present in less than an amount sufficient for complete combustion whereby the resulting weak gas (CO, CH₄, H₂) can be converted thermally to recover energy. The advantage resides in that the use of many fuels, especially even straw, is possible.

[0033] A method of operating a disposal plant for filter ash from garbage incinerators resides in that

[0034] ash from garbage incinerators is heated in a melting vat which is comprised of a ceramic with transition metal silicates and/or transition metal disilicates by heating above the melting point of the filter ash,

[0035] and the filter ash is vitrified (claim 15).

[0036] Ceramics with transition metal silicates and/or transition metal disilicates can thus be used in-general wherever liquid, SiO₂-rich slag must be separated from a flue gas stream at high temperatures or wherever ceramic material at high temperatures is in contact with an SiO₂-rich liquid.

[0037] As an example for a high melting point ceramic with monosilicate and a disilicate is a mixture in proportions of 1:1 of Y₂SiO₅ and Y₂Si₂O₇ whereby such a ceramic has a SiO₂ content of 58 mol % SiO₂. The ceramic can be produced by reaction sintering in a hot isostatic press. The resulting ceramic has the advantage that the monosilicate component is taken up by contact with a silicate-rich liquid SiO₂ whereby the surface porosity of the ceramic is minimized in situ. This increases stability of the ceramic against corrosion and minimizes the penetration of slag in the solid body. 

1. A method of precipitating SiO₂-rich slags from a flue gas stream by the use of a ceramic with at least one transition metal silicate and/or transition metal disilicate and through the use of a mixing gap between the transition silicate and/or the translation metal disilicate and the SiO₂ of the slag.
 2. The method according to claim 1, characterized by a transition metal from the third or fourth subgroup of the periodic table or from the lanthanide group.
 3. The method according to one of the preceding claims, characterized by a silicate of the formula M₂Si₅ or M₂Si₂O₇ with M=the transition metal.
 4. The method according to one of the preceding claims, comprising scandium, yttrium. lanthanum, cerium, samarium and/or dysprosium, predominantly as the metal oxide.
 5. The method according to one of the claims 1 or 2, characterized by a silicate of he formula MSiO₄ with M=the transition metal.
 6. The method according to claim 5, characterized by zirconium and/or hafnium predominantly as the metal oxide.
 7. The method according to one of the preceding claims, characterized by the use of a ceramic which contains 50 to 66 mol % SiO_(2.)
 8. A ceramic material according to one of the preceding claims, characterized by a melting point greater than 1500° C.
 9. A method according to one of the preceding claims, characterized in that the precipitation of SiO₂ rich slag is effected from the flue gas of a coal fired gas and steam power plant.
 10. A method according to claim 9, characterized by the steps of: burning fuel under pressure, guiding the hot gas onto a separating device which comprises a ceramic with transition metal silicate and/or transition metal disilicate, removing the liquid particles.
 11. The method according to one of claims 9 or 10, characterized by the use of the pressurized coal dust firing technology.
 12. The method according to one of the claims 1 to 8, characterized in that the precipitation of SiO₂-rich slag is effected from the flue gas of a coal, wood, biomass or clarifier sludge gasifier.
 13. The method according to claim 12, characterized by the steps of: gasifying or burning fuel substoichiometrically, guiding the hot gas onto a separating device which comprises a ceramic with transition metal silicate and/or transition metal disilicate, removing the liquid particles.
 14. The method according to one of the claims 1 to 8, characterized in that the precipitation of SiO₂-rich slag is effected from the flue gas of a disposal plant for filter ash from garbage incinerators.
 15. The method according to claim 14, characterized by the steps of: ash from garbage incinerators in a melting tub which comprises a ceramic with transition metal silicate and/or transition metal disilicate over the melting point of the filter ash, vitrifying the filter ash. 